Progressive die machine

ABSTRACT

An apparatus for serially making formed parts from a web of deformable material with a stud mounted therein having a plurality of progressive die forming stations for forming multiple parts from the web by advancing the web through each forming station. In one embodiment, the apparatus has feeding, driving and transfer mechanisms for controlling the feeding and insertion of studs at spaced locations into the web.

CROSS-REFERENCE TO RELATED APPLICATIONS

This Application claims the benefit of U.S. patent application Ser. No.60/049,847, filed Jun. 17, 1997.

BACKGROUND OF THE INVENTION

1. Field of the Invention

This invention relates to a progressive die machine having astud-feeding apparatus mounted thereto which is configured to drive astud, bolt, nut or other fastener into a web being passed through theprogressive die machine.

2. Description of the Related Art

Progressive die machines have long been known in the art to comprise afixed lower die and an upper die which is reciprocally movable withrespect to the lower die. The upper die is typically slidably mountedwithin rails which constrain the upper die to vertical movement therein.In addition, a motor having an output shaft is provided. The outputshaft typically has a distal end provided with a concentrically-mountedplate thereon which, in turn, has an eccentrically-mounted pin adjacentan outer radial edge thereof. Further, a ram is provided which has oneend mounted to an upper surface of the die and an opposite end having abearing which is journaled to the pin of the motor. Thus, as rotationalmotion is imparted to the output shaft by the motor, the pin is rotatedas well and traces a circular path. As a result, the ram, in conjunctionwith the upper die, is moved reciprocally within the rails with respectto the lower die.

Each rotation of the output shaft of the motor is referred to as the“stroke” of the machine and ranges between 0 and 360 degrees. Thus, thepoint at which the pin on the plate of the motor output shaft is locatedat the uppermost vertical position with respect to the plate is referredto as the 0 degree position or “top dead center” (TDC). At TDC, theupper die is positioned the greatest extent above the lower die. Thepoint at which the pin on the plate of the motor output shaft is locatedadjacent to the lowermost vertical position with respect to the plate isreferred to as the 180 degree position. In the 180 degree position, theupper die is positioned adjacent to the lower die and is the positionwhereby the forming operations are performed on the web. Between the 0and 180 degree positions, the upper die is lowered with respect to thelower die and between the 180 and 360 degree positions, the upper die israised with respect to the lower die.

The upper and lower dies cooperate to define several forming stationstherein. Each forming station includes an individual forming tool and adie which are configured and dimensioned so that a particularpredetermined operation can be performed on a web fed between the upperand lower dies. The web is typically an elongated strip of materialprovided as a feedable supply adjacent the machine, such as on a spool.The progressive die machine typically includes a feeding apparatusmounted adjacent the lower die which sequentially advances the webbetween the upper and lower dies and through each of the formingstations therein.

The number of forming stations is determined by the number of formingoperations necessary to form a desired part. A portion of each of theforming tools are located on the upper die and are driven in unison inreciprocal fashion by the ram. Thus, a forming operation is performed ateach forming station during each stroke of the ram.

Following each stroke, the web is advanced so that each portion of theweb is positioned within the next successive forming station in themachine. When a portion of the web has passed each forming station inthe progressive die machine, a desired part is formed. The last stationin the machine typically includes a severing tool and a discharge chute.The severing tool cuts the formed part from the web so that the formedpart can fall into the discharge chute and be accumulated therein.

The above-described machine typically forms a completed part. However,it has been found that some parts require additional manufacturingoperations to be performed thereon before the part is ready for shippingto customers. One such additional operation is the staking of a stud,such as a threaded fastener, into the formed part after it has beencompleted. Typically, an aperture is provided in the part by theprogressive die machine and the stud is located in the aperture afterthe progressive die machine has completed the forming process. Thestaking of the stud often requires an additional manufacturing apparatusand/or substantial human intervention to complete the part which can addto the per unit cost of producing the part. Prior art progressive diemachines have been insufficient in providing a solution to this problem.

In addition, the formed part may have a geometrical configuration whichmakes the staking of a stud therein prohibitively difficult. Forexample, a part can be provided with a C-shaped configuration wherebythe stud is desired to be located within an interior surface thereof.Depending upon the clearance provided within the interior surface, it isoften difficult to accurately stake the stud therein. Thus, the formedpart must either not include the stud or the formed part must be bent toa lesser a degree than is required. After the part has been formed bythe progressive die machine, the stud must be staked therein by aseparate apparatus and process, and then the part must be further bentto place the formed part within required tolerance limits.

Additional problems are encountered by the progressive die machines.Changes in a wide variety of uncontrollable characteristics can causethe formation of parts which do not fall within tolerances required by aparticular application for a part. Such tolerances can be of criticalimportance because a part which falls outside of these tolerances cancause a catastrophic failure in the system or machine in which the partis ultimately installed. Some examples of the uncontrollablecharacteristics encountered by prior art progressive die machinesinclude: changes in thickness in the web material from which the partsare formed, flaws in the web material, wear on the forming tools anddies and foreign matter located on the web material. Thesecharacteristics can cause the formation of unacceptable parts by theprogressive die machine which can often go undetected by the machine orits operator during use.

SUMMARY OF THE INVENTION

The invention relates to an apparatus for serially making formed partsfrom a web of deformable material with a stud mounted therein comprisinga plurality of progressive die forming stations for forming multipleparts from the web by advancing the web through each forming station, afeeding mechanism for feeding studs seriatim to a predetermineddispensing position adjacent to the web, a driving mechanism adjacent tothe web for inserting studs in spaced locations into the web, a transfermechanism operably connected to the feeding mechanism for receivingstuds from the feeding mechanism and for transferring studs to thedriving mechanism, and a cutting station for severing the web after theweb has passed through the die forming stations to separate the formedindividual stud-bearing parts from the web.

The driving mechanism can be located adjacent to one of the die formingstations whereby the studs are inserted into the web as the parts areformed in the progressive die forming stations. The die forming stationscan further comprise a movable die having a driving ram associatedtherewith to reciprocate the movable die between a retracted and adeforming position to deform the web as the web is advanced through theforming stations. The driving ram is preferably operably connected tothe driving mechanism to actuate the driving mechanism for inserting astud into the web when the movable die is moved between the retractedand deforming positions. The operable connection between the driving ramand the driving mechanism preferably comprises one of a flange and asocket disposed on the movable die, and the other of the flange and thesocket located on the driving mechanism whereby when the movable die ismoved between the retracted and the deforming positions the flange isreceived in the socket.

The feeding mechanism can be positioned adjacent one of the formingstations and is operably interconnected with the driving ram to indexthe seriatim feeding of the studs when the movable die is moved betweenthe retracted and deforming positions. The feeding mechanism cancomprise a shuttle car movable between a receiving position and adispensing position and having an opening for receiving one of the studstherein when in the receiving position. The opening in the shuttle caris preferably aligned with a conduit in the feeding mechanism. One endof the conduit is preferably aligned with the opening in the shuttle carwhen in the dispensing position and the other end of the conduit ispreferably aligned with the transfer mechanism. The shuttle car can havea cam follower and a cam operably connected to the driving ram inregister with the cam follower for moving the shuttle car from thereceiving position to the dispensing position as the movable die movesbetween the retracted and deforming positions.

The feeding mechanism can further comprise an actuator mounted adjacentto the shuttle car and adapted to move the stud out of the opening inthe shuttle car into the conduit when the shuttle car is moved to thedispensing position. The actuator can comprise a pressurized air nozzlein register with the opening of the shuttle car in the dispensingposition whereby air exiting the nozzle moves the stud into the conduit.The feeding mechanism can further comprise a lever mounted adjacent toan end of the conduit having a stop thereon movable between anobstructing position and a release position and a cylinder having anaxially-movable piston having an actuator portion thereon in registerwith the lever. The piston is preferably movable between a firstposition wherein the actuator portion positions the lever in theobstructing position and a second position wherein the actuator portionpositions the lever in the release position and forces the stud out ofan exit of the conduit and into the transfer mechanism. The piston canfurther comprise a stud-receiving indentation which receives the stud asthe piston moves from the first position to the second position forrestricting the movement of the stud in a single linear direction.

The transfer mechanism can be positioned adjacent one of the formingstations and operably interconnected with the driving ram to index theseriatim feeding of the studs between the feeding mechanism and thedriving mechanism when the movable die is moved between the retractedand deforming positions. The transfer mechanism can comprise a supportplate and at least one set of gripping members mounted to the supportplate and adapted to selectively grip a stud. The support plate ispreferably mounted for movement of the at least one set of grippingmembers between the feeding mechanism and the driving mechanism. The atleast one set of gripping members receive and grip a stud from thefeeding mechanism, travel with the support plate to the drivingmechanism, and release the stud at the driving mechanism. The transfermechanism can further comprise an arm mounted to the support platethrough a ratchet mechanism to selectively position the support plate ata number of discrete positions between the feeding mechanism and thedriving mechanism. The arm can have a flange operably coupled to thedriving ram so that the arm positions the support plate at a nextdiscrete position as the movable die moves between the retracted anddeforming positions. The at least one set of gripping members cancomprise multiple sets of gripping members mounted to the support plate.One of the sets of gripping members can be positioned at the feedingmechanism while another of the sets of gripping members can besimultaneously positioned at the driving mechanism at each discreteposition of the support plate.

The driving mechanism is preferably positioned adjacent one of theforming stations and is operably interconnected with the driving ram toindex the seriatim insertion of the studs into the web when the movabledie is moved between the retracted and deforming positions. The drivingmechanism can comprise a driving mechanism housing, a hammer slidablymounted within the housing and adjacent to the transfer mechanism forforcing each of the studs into the web, and a lever mounted to thehousing for movement between a rest position and an insertion positionand having a first end and a second end. The first end is operablyconnected to the driving ram and the second end is in register with thehammer. The hammer receives one of the studs when the lever is in therest position and is moved by the lever to insert the stud into the webwhen the lever moves between the rest and insertion positions. The leveris moved between the rest position and the insertion position when themovable die is moved between the retracted position and the deformingposition.

The die forming stations can further comprise a movable die having adriving ram associated therewith to reciprocate the movable die betweena retracted and a deforming position to deform the web as the web isadvanced through the forming stations. The driving ram preferably isoperably connected to the driving mechanism to actuate the drivingmechanism for inserting a stud into the web when the movable die ismoved between the retracted and deforming positions. The operableconnection between the driving ram and the driving mechanism preferablycomprises one of a flange and a socket disposed on the movable die, andthe other of the flange and the socket located on the driving mechanism.Thus, when the movable die is moved between the retracted and thedeforming positions, the flange is received in the socket.

In an additional aspect, the invention relates to a method for seriallymaking formed parts from a web of deformable material with a studmounted therein comprising the steps of providing a plurality ofprogressive die forming stations for forming multiple parts from theweb, advancing the web through each forming station, feeding multiplestuds seriatim to a predetermined dispensing position adjacent to theweb, inserting each stud at spaced locations into the web, and severingthe web after the web has passed through the die forming stations toseparate the formed individual stud-bearing parts from the web.

The method can comprise additional steps such as: providing a movabledie with a driving ram associated therewith, and reciprocating themovable die between a retracted and a deforming position to deform theweb as the web is advanced through the forming stations. At least onestud can be indexed toward the dispensing position when the movable dieis moved between the retracted and deforming positions. At least onestud can be inserted into the web when the movable die is moved betweenthe retracted and deforming positions. A stud can be moved from thedispensing position to an insertion position adjacent to the web whenthe movable die is moved between the retracted and deforming positions.The dimensional relationship between the first and second dies in thedeforming position can be adjusted responsive to a remote signal.

Other objects, features, and advantages of the invention will beapparent from the ensuing description in conjunction with theaccompanying drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

In the drawings:

FIG. 1 is a diagrammatic view from a side elevational perspectiveshowing a progressive die machine according to the invention which has astud-staking apparatus, a bending apparatus, and a measuring apparatuslocated adjacently or mounted thereto;

FIG. 2 is a fragmentary top plan view of a portion of a lower die of theprogressive die machine of FIG. 1 which illustrates a stud-stakingassembly contained therein and has a portion of the lower die shown incross section to provide a clear illustration of the assembly;

FIG. 3 is an enlarged fragmentary top plan view of the stud-stakingassembly shown in FIG. 2 provided with a portion thereof in crosssection to provide additional illustration of a cylinder urging an infedstud into engagement with a rotary feed mechanism located adjacentlythereto;

FIG. 4 is cross-sectional view of the stud-staking assembly taken alonglines 4—4 of FIG. 2 showing a stud positioned in a conduit while anupper die is in a raised position with respect to the lower die of theprogressive die machine;

FIG. 5 is a cross-sectional view of the stud-staking assembly takenalong lines 5—5 of FIG. 2 showing the stud positioned in a conduit whilethe upper die is in a lowered position with respect to the lower die ofthe progressive die machines;

FIG. 6 is an enlarged perspective view of a slidable car shown in FIGS.4-5 which is adapted to be moved by the upper die during operation ofthe progressive die machine;

FIG. 7 is a side elevational view of the rotary feed mechanism of FIG. 2shown with the upper die in a raised position with respect to the lowerdie;

FIG. 8 is a side elevational view of the rotary feed mechanism of FIG. 2shown with the upper die in a lowered position with respect to the lowerdie whereby a stud is urged into a web material passing between theupper and lower dies;

FIG. 9 is an enlarged perspective view of a lever and rotatable plateportion of the rotary feed mechanism of FIG. 2;

FIG. 10 is a cross-sectional view of the rotary feed mechanism of FIG. 2showing the interengagement of a pin on a housing with an aperture onthe rotatable plate;

FIG. 11 is an enlarged end view of the pin of FIG. 10;

FIG. 12 is a diagrammatic side elevational view of a pair of grippingarms on the rotary feed mechanism shown in receipt of a stud therein;

FIG. 13 is a diagrammatic side elevational view of the gripping arms ofFIG. 12 shown biased into an open position wherein a stud is releasedfrom retention therein;

FIG. 14 is a side elevational view of a stud-driving assembly which isshown adapted to drive a stud into the web material passing between theupper and lower dies;

FIG. 15 is a rear elevational view of the stud-driving assembly of FIG.14;

FIG. 16 is a front elevational view of the bending apparatus of FIG. 1shown in a lowered position with respect to the upper die;

FIG. 17 is a diagrammatic front view of the bending apparatus of FIG. 16shown in a raised position;

FIG. 18 is a front cross-sectional view of the measuring apparatus ofFIG. 1;

FIG. 19 is a diagrammatic view of the measuring apparatus of FIG. 18;and

FIG. 20 is a diagrammatic view of the stroke of the progressive diemachine of FIG. 1.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

Referring now to the drawings and to FIG. 1 in particular, a progressivedie machine 10 is shown comprising a lower die 12 and an upper die 14which is connected to a ram 16. It will be understood that theprogressive die machine 10 is generally configured and operates asdescribed in the “Background of the Invention” section. Thus, it will befurther understood that the ram 16 is interconnected to a conventionalmotive apparatus (not shown) which imparts a reciprocal motion to theram 16. The reciprocal motion imparted to the ram 16 in turnreciprocates the upper die 14 with respect to the lower die 12 inaccordance with what is generally known to those skilled in the artrelating to progressive die machines.

A web of material 18 is shown in FIG. 1 being fed longitudinally betweenthe lower and upper dies 12 and 14, respectively. Further, severalforming stations are formed on the lower and upper dies 12 and 14, someof which are shown by reference numerals 20-36. A progressive diemachine 10 further includes an advancing mechanism (not shown) wherebythe web 18 is advanced between the lower and upper dies 12 and 14 indiscrete steps so that a particular portion of the web 18 is positionedadjacent each of the forming stations 20-36. It will be understood thatthe forming stations 20-36 perform a particular tooling, contouring, orother forming operation on a particular portion of the web 18. It willbe further understood that additional or fewer forming stations 20-36can be provided without departing from the scope of this invention. Itwill also be understood that the forming stations 20-36 can also be idlestations or have other functions besides forming.

FIG. 1 shows the web 18 having several individual portions thereoflocated adjacent forming stations 20-36. The web 18 is shown beingformed into a part having a stud 38 mounted into the web at formingstation 20 and eventually being bent into a C-shaped configuration bylater forming stations. The staking of the stud 38 into the web 18 atforming station 20 is performed by a stud-staking apparatus 42 which isdescribed in greater detail below and shown in FIGS. 2-15.

The part 40, having the stud 38 staked therein, is finally formed into aC-shaped configuration as it approaches forming station 32 by a bendingapparatus 44 which performs a final bending operation on the part 40 toprovide the C-shaped configuration thereto. A measuring apparatus 46 islocated downstream from the forming stations 20-36. The measuringapparatus 46 measures the final dimensions of each part 40 passingtherethrough and provides a signal through feedback loop 48, which, inturn, signals a PLC 50 to control the bending apparatus 44. The PLC 50notes dimensions or other characteristics measured by the measuringapparatus 46 and determines whether the parts 40 passing through themeasuring apparatus 46 are within a set of predetermined tolerancelimits. It will be understood that, although the measuring apparatus 46is shown between the lower and upper dies 12 and 14, the measuringapparatus can also be a separate component located downstream therefrom.

If the parts 40 passing through the measuring apparatus are not withinthe predetermined tolerance limits, the PLC 50 sends a signal to thebending apparatus 44 to provide a greater or lesser degree of bending tothe part 40 located at the bending apparatus 44. All parts 40 later fedthrough the bending apparatus 44 are thereby formed by the bendingapparatus in accordance with the signal from the PLC 50. The bendingapparatus 44 is shown in FIGS. 16-17. The measuring apparatus 46 isshown in FIG. 18. This process is described in greater detail in FIG.19.

As shown in FIGS. 2-15, the stud-staking apparatus 42 comprises apositioning mechanism 52 and a staking mechanism 54. The positioningmechanism 52 is adapted to receive a stud 38 and position the stud 38within the staking mechanism 54 whereby the staking mechanism 54 canthen mount the stud 38 within a part 40 formed within the web 18.

The positioning mechanism 52 is shown in detail in FIGS. 2-3 andcomprises an elongated body 56 having a first end 58 and a second end60. The first end 58 of the body 56 includes a transverse passage 62which extends laterally across the elongated body 56. The passage 62 hasa first end 64 and a second end 66. An aperture 68 is formed in thefirst end 58 of the body 56 which extends into the passage 62intermediate the first and second ends 64 and 66 thereof. The aperture68 extends into a conduit 70 which extends axially from the first end 58of the body 56 and is interconnected by a fitting 72 to a source ofpressurized fluid, preferably air. It will be understood that the sourceof pressurized air interconnected to fitting 72 can either be suppliedas a continuous stream or as intermittent bursts of air as required.

As shown in FIGS. 2-3 and in greater detail in FIGS. 4-5, a conduit 74extends upwardly from the first end 58 of the body 56 and is incommunication with the first end 64 of the passage 62 therein. It willbe understood that the conduit 74 is of sufficient size to allow a stud38 to travel axially therethrough without restriction. The conduit 74has a first end 76 and a second end 78. The first end 76 is preferablyinterconnected to a supply of studs 38 whereby the studs 38 can beselectively supplied to the first end 76 of the conduit 74. It will beunderstood that the supply of studs interconnected to the first end 76of the conduit 74 can comprise a magazine of studs, a manual supply, oran automatic supply whereby studs are supplied to the first end 76 ofthe conduit 74 such as by compressed air being blown behind the stud sothat the stud 38 travels toward the second end 78 of the conduit 74. Thesecond end 78 of the conduit 74 can be provided with aninwardly-extending frustoconical wall as shown in FIGS. 4-5 so that astud 38 is centered axially with respect to the second end 78 of theconduit 74 as the stud 38 enters therein.

A car 80 is slidably mounted to the first end 58 of the body 56 so thatthe car 80 can traverse generally parallel with the passage 62 therein.As shown in FIGS. 4-5 and in greater detail in FIG. 6, the car 80comprises an elongated body 82 having a first end 84 and a second end86. The car 80 further is provided with an upper surface 88 thereon. Theupper surface 88 is provided with a first aperture 90 adjacent the firstend thereof. The first aperture 90 extends downwardly within the body 82of the car 80 into a bore 92 which has a lateral cross section adaptedto substantially conform to an outline shape of a stud 38. The secondend 86 of the body 82 has a laterally- and forwardly-extending flange 94which is provided with a ramped surface 98 which, in turn, terminates ina vertical surface 100.

The car 80 is mounted for slidable movement to the first end 58 of thebody 56 between a first and a second position as shown in FIGS. 4 and 5,respectively. A spring 178 is mounted adjacent the second end 86 of thecar 80 and the first end 58 of the body 56. A distal end 182 of thespring 178 abuts the second end 86 of the car 80 and biases the car 80axially outwardly with respect to the spring 178.

In the first position shown in FIG. 4, the progressive die machine 10 isin an open position wherein the upper die 14 is in a raised positionwith respect to the lower die 12. As shown in FIG. 4, the upper die 14is provided with a downwardly-depending flange 184 having a distal end186 provided with an angular surface 188 thereon. The angular surface188 of the flange 184 preferably conforms generally with the angularorientation of the ramped surface 98 of the car 80. When the upper die14 is raised with respect to the lower die 12, the flange 184 does notcontact the car 80. Thus, the outward bias of the spring 178 causes thecar 80 to be biased into the first position wherein the aperture 90 andbore 92 of the car 80 are concentrically aligned with the second end 78of the conduit 74. Thus, a stud 38 can be delivered through the firstend 76 of the conduit 74 and into the bore 92 of the car 80 through thesecond end 78 of the conduit 74.

In the second position shown in FIG. 5, the upper die 14 has beenlowered with respect to the lower die 12 which, in turn, lowers theflange 184 with respect to the car 80. As the flange 184 is lowered, theangular surface 188 on the distal end 186 of the flange 184 is loweredas well so that the angular surface 188 of the flange 184 contacts theramped surface 98 of the flange 94. As the upper die 14 moves toward thelower die 12, the downward urging of the angular surface 188 of theflange 184 against the ramped surface 98 of the flange 94 causes the car80 to be moved toward the second position shown in FIG. 5 which alsourges the second end 86 of the car 80 against the distal end 182 of thespring 178. The distal end 186 of the flange 184 eventually is lowered asufficient extent so that the flange 184 abuts the vertical surface 100of the flange 94 and retains the car 80 in the second position shown inFIG. 5 whereby the bore 92 is aligned with an axial conduit 108 in thebody 56. Further, the laterally-extending bore 105 is aligned with theconduit 70 via aperture 68.

When the upper die 14 is raised with respect to the lower die 12, thedistal end 186 of the flange 184 is retracted from contact with theflange 94 on the car 80. Once the flange 184 has been lifted asufficient extent, the angular surface 188 on the distal end 186 thereofonce again abuts the ramped surface 98 of the flange 94 which causes thecar 80 to be slid towards the first position in conjunction with theoutwardly biased distal end 182 of the spring 178 acting against thesecond end 86 of the car 80. Once the flange 184 is lifted out ofengagement with the flange 94, the car 80 is biased into the firstposition once again by the spring 178 as shown in FIG. 4.

The conduit 108 extends between the first and second ends 58 and 60 ofthe body 56 which has a first end 110 and a second end 112. The firstend 110 of the conduit 108 is preferably concentrically aligned with theaperture 68 in the first end 58 of the body 56. The second end 112 ofthe conduit 108 preferably includes a curved turn 114 which, in turn,terminates in a lateral extension 116. The conduit 108 is defined bysidewalls 118 which preferably have a cross section substantiallyconforming to that of a stud 38. In addition, the sidewalls 118 eachinclude a laterally-extending ledge 120 which is adapted to receive aradially-extending body of a stud 38 so that a stud 38 can slide throughthe conduit 108 in a controlled fashion without accidentally becominglodged therein. It will be understood that the conduit 108 interconnectsthe passage 62 in the first end 58 of the body 56 with the stakingmechanism 54 located adjacent an exit point of the lateral extension 116in the second end 60 of the body 56.

As shown in FIG. 3, the second end 60 of the body 56 further includes atransverse passage 122 which extends laterally outwardly from the secondend 60 of the body 56 preferably in axial alignment with the lateralextension 116 of the conduit 108. A cylinder 124 having a piston 126 ismounted to the body 56 in concentric alignment with the passage 122 inthe second end 60 thereof. A distal end 128 of the piston 126 isprovided with a rounded indentation 130. A radius of curvature of theindentation 130 preferably generally corresponds with an outer radius ofa body of a stud 38. It will be understood that the piston 126 isaxially movable with respect to the cylinder 124 between a firstposition wherein the distal end 128 of the piston 126 is positionedwithin the passage 122 and a second position wherein the distal end 128of the piston 126 is extended within the lateral extension 116 of theconduit 108 a sufficient extent to urge a stud 38 located within thelateral extension 116 outwardly therefrom.

The distal end 128 of the piston 126 is preferably of a width whichextends substantially across the width of the passage 122 in the secondend 60 of the body 56. At a point intermediate the distal end 128 of thepiston 126 and the cylinder 124, the width of the piston 126 preferablydecreases to a narrow portion 132. The transition from the wider distalend 128 of the piston 126 and the narrow portion 132 of the piston 126is preferably formed by a ramped surface 134 as shown in FIG. 3.

As shown in FIG. 2, it will be understood that the cylinder 124 ispreferably a pneumatic cylinder whereby the introduction of pressurizedfluid to an end 136 of the cylinder 124 causes the piston 126 to beaxially extended therefrom. The cylinder 124 preferably has a returnspring (not shown) located therein to retract the piston 126 within thecylinder 124 when the pressure of the fluid acting on the end 136 of thecylinder 124 is reduced to a sufficient degree. The cylinder 124 ispreferably interconnected to a source of pressurized fluid, such as air,by conduits 138 and 140 which preferably have a relief valve 142positioned therebetween. A fitting 144 on an opposite end 146 fluidlyinterconnects the conduit 140 to a manifold 148 which has an additionalfitting 150 interconnected to the source of pressurized fluid. It willbe understood that the relief valve 142 is preferably a dischargefacility for pressurized air which, when actuated, relieves any backpressure in the conduit 138 to the atmosphere which allows the piston126 to retract quickly within the cylinder 124. Thus, the piston 126 canbe extended and retracted from the cylinder 124 at a high velocity in arelatively short period of time. After the burst is relieved by therelief valve 142, the supply of pressurized air can be recharged fromthe manifold 148.

Referring now to FIG. 3, the second end 60 of the body 56 furtherincludes a recess 152 located intermediate the lateral extension 116 andpassage 122 and the second end 60 of the body 56. The recess 152preferably extends laterally across the second end 60 thereof and hasfirst and second openings 154 and 156 which interconnect the recess 152with the passage 122 and the lateral extension 116, respectively. Alever 158 is pivotably-mounted within the recess 152 to the body 56 by apin 160 located intermediate the first and second openings 154 and 156.The lever 158 comprises an elongated body 162 having a first end 164 anda second end 166. Each of the first and second ends 164 and 166 of thebody 162 is provided with a flange 168 thereon, each of which extendstoward the first end 58 of the body 56.

The lever 158 is pivotable between a first position wherein the flange168 on the first end 164 of the body 162 extends into the passage 122and a second position wherein the flange 168 on the second end 166 ofthe body 162 extends into the lateral extension 116. It will beunderstood when the lever 158 is located in the second position theflange 168 on the second end 166 of the body 162 extends into thelateral extension 116 a sufficient extent so as to prevent a stud 38from exiting therefrom.

As the piston 126 is extended from the cylinder 124, the stud 38 isurged against the flange 168 of the second end 166 and causes the stud38 to pivot the lever 158 out of obstruction of the lateral extension116. The lever 158 is allowed to pivot because the extension of thepiston 126 brings the narrow portion 132 into alignment with the firstend 164 providing clearance therefor.

As shown in FIGS. 1-3 and in greater detail in FIGS. 7-15, the stakingmechanism 54 includes a rotary feed mechanism 190 mounted adjacent theexit point of the lateral extension 116 in the second end 60 of the body56. The rotary feed mechanism 190 comprises a cylindrical body 192having a circular plate 194 rotatably mounted thereto. The plate 194 hasseveral gripping members 196 positioned adjacent an outer radial edge198 of the plate 194. It will be understood that the figures show eightgripping members 196 mounted in a spaced relationship to the plate 194about edge 198, however, additional or fewer gripping members 196 can bemounted to the plate 194 without departing from the scope of thisinvention. The gripping members 196 are preferably mounted to the plate194 so that a pair of gripping members 196 are located directly oppositefrom one another along a diametrical axis which passes through thecenter of the plate 194. It will be understood that a gripping member196 can be positioned adjacent the lateral extension 116 of the conduit108 at the second end 60 of the body 56 whereby a stud 38 exiting thelateral extension 116 is received directly by the gripping member 196positioned adjacently thereto. It will be further understood that agripping member 196 located on the opposite side of the plate 194 ispositioned in an inverted orientation directly beneath the web 18 atforming station 20.

Referring to FIGS. 7-9, the plate 194 of the rotary feed mechanism 190is rotatably mounted upon a shaft 200 of a housing 202. It will beunderstood that the housing 202 can be fixedly mounted to the lower die12 or can be provided with its own support adjacently thereto withoutdeparting from the scope of this invention. In addition to the plate194, the rotary feed mechanism 190 further comprises a ratchet 204, alever 206, and a stud-driving assembly 208 (see FIGS. 14 and 15 ).

The ratchet 204 is provided on a rearward surface of the plate 194 inconcentric alignment with the shaft 200 and has severaltangentially-extending teeth 210 thereon. The teeth 210 are each definedby a ramped surface 212 which extends tangentially and radiallyoutwardly from a body 214 of the ratchet 204 and terminates in a roundedpeak 216. A side of the peak 216 opposite from the ramped surface 212extends radially toward the body 214 and terminates in a rounded groove218. Each groove 218 extends smoothly into the ramped surface 212 of thenext successive tooth 210 on the ratchet 204. It will be understood thatthe number of teeth 210 on the ratchet 204 preferably corresponds to thenumber of gripping members 196 provided on the plate 194.

The lever 206 comprises an elongated body 220 which has a centralaperture 222 journaled upon the shaft 200 and having a first end 224 anda second end 226. The lever 206 further has a forward surface 228 facingthe plate 194 and a rearward surface 230 facing the ratchet 204.

The first end 224 of the body 220 of the lever 206 is preferablyprovided with a laterally-extending rounded flange 232 which ispreferably mounted to one of the lower die 12 and the housing 202 via abiasing member 234 which biases the first end 224 of the lever 206 in acounterclockwise fashion about the shaft 200. The lever 206 ispreferably movable between a raised position and a lowered position withrespect to the shaft 200 as shown in FIGS. 7 and 8, respectively.

As shown in FIGS. 9-11, the forward surface 228 of the second end 226 ofthe lever 206 is provided with a forwardly extending flange 236. Theflange 236 preferably has a forward surface 238 thereon which protrudestherefrom between a first end 240 and a second end 242.

As shown in FIGS. 7-9, a laterally-extending flange 242 is provided onthe elongated body 220 of the lever 206 intermediate the first andsecond ends 224 and 226 thereof. The flange 224 has a rounded distal end246. A latch 248 having a first end 250 and a second end 252 ispivotably mounted to the distal end 246 of the flange 244 adjacent theforward surface 228 thereof. The pivotable mounting of the latch 248 tothe flange 244 can be accomplished in any conventional manner such as bya pin 254 mounted within an aperture 256 as shown in FIG. 9. The secondend 252 of the latch 248 preferably has a rounded end which preferablycorresponds in outer radius to the groove 218 of the teeth 210 in theratchet 204. A torsion spring 257 is provided between the lever 206 andthe latch 248 which biases the latch 248 into a corresponding groove218.

The plate 194 has a radial groove 195 therein which has several pins 272(see FIGS. 10-11 ) located in a spaced circumferential relationship. Thepins 272 extend through each of the gripping members 196 and preventovertravel thereof when the gripping members 196 close.

The plate 194 of the rotary feed mechanism 190 is preferably discretelylockable in a number of positions whereby each of the gripping members196 can be positioned adjacent both the exit point of the lateralextension 116 of the conduit 108 of the positioning mechanism 52 andadjacent the point at which the stud 38 is staked into the web 18adjacent the opposite portion of the plate 194. This location of thevarious positions of the plate 194 is accomplished by a locatingmechanism 258 mounted to the housing 202 as shown in FIG. 10. Thelocating mechanism 258 comprises a pin 260 having a central portionprovided with a radially-extending lip 262. The pin 260 is mountedwithin a bore 264 of the housing 202 and biased outwardly therefrom by aspring 266. The pin 260 preferably has a distal end provided with arounded cam surface 268 thereon.

The plate 194 further comprises a set of apertures 270. The set ofapertures 270 are located adjacent the radial edge 198 of the plate 194and are located at each portion of the plate 194 containing a grippingmember 196 and are adapted to receive the pin 260 of the locatingmechanism 258 so that, as the plate 194 rotates, the pin 260 in thelocating mechanism 258 can engage successive apertures 270 in the plate194.

A stud 38 contained in a gripping member 196 is rotated about the shaft200 and moved from a position adjacent the lateral extension 116 of theconduit 108 through a number of discrete positions to a position wherebythe stud can be inserted into the web 18 by the stud-driving assembly208. The lever 206 is mounted upon the shaft 200 so that the latch 248,pivotably mounted to the rearward surface 230 of the flange 244, isengaged within a groove 218 of one of the teeth 210 on the ratchet 204and held in place by the bias of the spring 257. The pin 260 is biasedoutwardly of the bore 264 and is positioned within one of the apertures270 on the plate 194 to retain the plate 194 in a particular discreteposition.

As shown in FIGS. 14-15, the stud-driving assembly 208 is preferablymounted adjacent the plate 194 on an opposite side thereof from thelever 206 so that the action of the stud-driving assembly as it stakes astud 38 within the web 18 does not interfere with the rotation of theplate 194 or the other components of the staking mechanism 54. Thestud-driving assembly 208 comprises a housing 470, a lever 472, and ahammer 474.

The housing 470 comprises a body 476 which can be formed integrally withthe lower die 12 or as a separate component mounted adjacently theretowhich has a longitudinal recess 478, and a lateral recess 480. The lever472 is mounted within the longitudinal recess 478, and the hammer 474 ismounted within the lateral recess 480.

The lever 472 comprises an elongated body 482 having a first end 484 anda second end 486. The first end 484 of the lever 472 is provided with arounded flange 488 thereon. The second end 486 of the lever 472 is alsoprovided with a rounded flange 490. The lever 472 is pivotably mountedto the body 470 within the recess 478 in any conventional manner such asby a pin 492 mounted to the housing 470 which extends through anaperture 494 in the elongated body 482.

The hammer 474 comprises a body 496 provided with a recess 498configured to receive the rounded flange 490 on the second end 486 ofthe lever 472. The body 496 of the hammer 474 further includes alaterally-extending beam 500 which has a distal end 502 provided with avertical extension 504 thereon. The extension 504 has a distal end 506which is adapted to contact a radially-extending body of a stud 38.

In assembly, the hammer 474 is slidably mounted within the lateralrecess 480 of the housing 470 for slidable movement therein between alowered position and a raised position as shown in FIG. 14. The roundedflange 490 of the second end 486 of the lever 472 is positioned withinthe recess 498 of the hammer 474 so that pivotable movement of the lever472 actuates the hammer 474 between the lowered and raised positions. Aspring 508 can be mounted in any suitable position, such as between thehousing 470 and hammer 474, to bias the hammer 474 into the loweredposition. The rounded flange 488 on the first end 484 of the lever 472preferably extends beyond the longitudinal recess 478 of the housing 470and is adapted to be contacted by a depending flange 510 provided as aportion of a forming tool on the upper die 14. Thus, as the upper die 14is moved toward the lower die 12, the depending flange 510 contacts therounded flange 488 on the first end 484 of the lever 472 and urges thefirst end 484 downwardly. This causes the lever 472 to be pivoted aboutthe pin 492 and urges the rounded flange 490 on the second end 486upwardly. Because the rounded flange 490 of the second end 486 of thelever 472 is engaged within the recess 498 on the hammer 474, the hammer474 is urged upwardly in conjunction with the second end 486.

It will be understood that, when the second end 486 of the lever 472 isin a lowered position, the distal end 506 of the extension 504 of thehammer 474 is positioned beneath the gripping member 196 locateddirectly beneath the web 18. As the second end 486 of the lever 472 ispivoted upwardly by the action of the depending flange 510 against thefirst end 484 of the lever 472, the hammer 474 is urged upwardly aswell. The distal end 506 of the extension 504 of the hammer 474 therebycontacts the radially-extending body of the stud 38 retained within thegripping member 196 and urges the stud 38 out of the gripping member 196and into the web 18. It will be understood that the stud 38 canpreferably include an annular groove 512 adjacent the body of the stud38 to aid the interengagement of the stud 38 with the web 18 as shown inFIG. 15.

The gripping members 196 are preferably adapted to releasably retain astud 38 therein, but upon sufficient force provided to theradially-extending body of the stud 38, the gripping members 196 areadapted to release the stud 38 therefrom. FIGS. 12-13 show the grippingmembers 196 in greater detail. The gripping members 196 comprise firstand second arms 280 and 282, respectively, each of which is pivotablymounted to the plate 194 by a pin 284 mounted within an aperture 286located in each of the arms 280 and 282. A spring 288 extends betweenthe first and second arms 280 and 282 to bias the arms 280 and 282 intoa closed position wherein the arms 280 and 282 are positioned directlyadjacent one another. In the closed position, the arms 280 and 282 canretain a stud 38 therebetween.

Each of the arms 280 and 282 include a raised wall 290 having a camsurface 292 thereon. The wall 290 and cam surface 292 are preferablyformed on the arms 280 and 282 in a mirror image of one another. Thus,it will be understood that whether a stud 38 is urged laterally oraxially between the raised walls 290 on the first and second arms 280and 282, the urging of the body of the stud 38 against the raised walls290 causes the stud 38 to force the first and second arms 280 and 282apart against the bias of the spring 288. Once the stud 38 clears thecam surface 292 thereon, the bias of the spring 288 biases the first andsecond arms 280 and 282 back to the closed position and closes the arms280 and 282 around the stud 38 to retain the stud 38 therebetween.Indentations 294 are provided on each arm 280, 282 which are closedaround a corresponding pin 272 on the plate 194 to prevent overtravel ofthe arms 280, 282 as they close.

The operation of the stud-staking apparatus 42 will now be described asshown in FIGS. 2-15. Referring to FIGS. 2-6, a stud 38 is fed throughthe first end 76 of the conduit 74 and into the bore 92 of the car 80via the second end 78 of the conduit 74. As the upper die 14 is loweredtoward the lower die 12, the distal end 186 of the flange 184 abuts theflange 94 on the car 80. As the upper die 14 is further lowered, theangular surface 188 on the flange 184 contacts the ramped surface 98 ofthe flange 94 on the car 80. The action of the angular surface 188 ofthe flange 184 against the ramped surface 98 causes the car 80 to bemoved toward the second end 66 of the passage 62 in the first end 58 ofthe body 56 as shown in FIGS. 2, 4 and 5.

When the stud 38 in the bore 92 is aligned with the aperture 68 in thepassage 62, pressurized air is supplied through the aperture 68 viaconduit 70 and fitting 72 to the bore 92 in the car 80. This causes thestud 38 to be “blown” into the conduit 108 in the body 56.

The radially-extending head of the stud 38 preferably rests on the ledge120 of the side walls 118 of the conduit 108. The stud 38 travelsthrough the conduit 108 via the burst of pressurized air suppliedthrough the conduit 70.

It will be understood that the piston 126 of the cylinder 124 ispositioned in the retracted position so that the distal end 128 thereofdoes not extend into the lateral extension 116 of the conduit 108. Thestud 38 travels toward the second end 60 of the body 56 and through theturn 114 and into the lateral extension 116. The flange 168 located onthe second end 166 of the lever 158 extends into the lateral extension116 and prevents the stud 38 from exiting the lateral extension 116.

When it is desired to insert the stud 38 located in the lateralextension 116 into a gripping member 196 of the rotary feed mechanism190, the cylinder 124 is supplied with a burst of pressurized air fromthe conduit 138 via the end 136 thereof. The piston 126 is axiallyextended from the cylinder 124. As the piston 126 is extended, theflange 168 on the first end 164 of the lever 158 rides against thepiston 126. The flange 168 of the first end 164 of the lever 158 isfurther urged along the ramped surface 134 of the piston 126 as a resultof the extension thereof. As the flange 168 passes the ramped surface134 and onto the narrow portion 132 thereof, the distal end 128 of thepiston 126 extends into the lateral extension 116 of the conduit 108. Inaddition, as the piston 126 is urged forwardly, it contacts the stud 38and pushes it forwardly, causing the lever 158 to be pivoted about pin160. As a result, the flange 168 of the second end 166 of the lever 158is pivoted out of obstruction of the lateral extension 116. The lever158 is allowed to pivot because the narrow portion 132 has beenpositioned adjacent the second end 166 due to the movement of the piston126. The narrow portion 132 provides the necessary clearance to allowthe stud 38 to be pivoted out of the lateral extension 116.

As the piston 126 is further extended from the cylinder 124, theindentation 130 on the distal end 128 of the piston 126 further pushesthe stud 38 located in the lateral extension 116. The piston 126 isextended so that the stud 38 is engaged within the rounded indentation130 and is pushed out of the lateral extension 116 of the conduit 108and into the gripping member 196 located adjacent the exit of thelateral extension 116.

Once a stud 38 has been positioned onto a gripping member 196, it is thefunction of the rotary feed mechanism 190, and particularly the plate194, to carry the stud 38 retained within the gripping members 196 froma position adjacent the exit of the lateral extension 116 of the conduit108 to a position whereby the hammer 474 on the stud-driving assembly208 can push the stud 38 into the web 18 to complete the staking of thestud 38 therein. As shown in FIGS. 7-8, several gripping members 196 areshown intermediate these two positions which carry studs 38 awaitinginsertion into the web 18.

The rotation of the plate 194 through its discrete positions will now bedescribed. It will be understood that the second end 252 of the latch248 of the lever 206 is engaged within a groove 218 of one of the teeth210 of the ratchet 204 which thereby retains the lever 206 in aparticular position with respect to the ratchet 204 as shown in FIGS.7-8 and in greater detail in FIG. 9. The plate 194 is releasably engagedto the lever 206 by the locating mechanism 258. More particularly, thecam surface 268 on the pin 260 is biased outwardly of the bore 264 inthe housing 202 by the spring 266. As shown in FIG. 10, the pin 260 islodged within one of the first apertures 270 on the plate 194 to retainthe plate 194 in a desired locked position with respect to the housing202.

The upper die 14 is preferably provided with a downwardly-dependingflange 294 having a distal end 296 provided on the forming stationlocated adjacent the rotary feed mechanism 190 as shown in FIGS. 7-8. Asthe upper die 14 is moved toward the lower die 12, the distal end 296 ofthe flange 294 contacts the rounded flange 232 on the first end 224 ofthe lever 206 and urges it downwardly. As the first end 224 of the lever206 is pivoted downwardly, the distal end 252 of the latch 248 travelsupwardly along the ramped surface 212 of the next successive tooth 210on the ratchet 204. When the first end 224 is pivoted downwardly asufficient extent by the flange 294 on the upper die 14, the distal end252 of the latch 248 passes over the peak 216 on the next successivetooth 210 and is urged falls by the bias of spring 257 into the groove218 of the next successive tooth 210 of the ratchet 204.

Once the flange 294 of the upper die 14 is lifted away from the lowerdie 12, the first end 224 of the lever 206 is again biased toward itsraised position. As the first end 224 of the lever 206 travels towardsthe raised position, the distal end 252 of the latch 248 is engagedwithin the groove 218 of the next successive tooth 210 of the ratchet204. As the first end 224 of the lever 206 travels toward the raisedposition, the engagement of the distal end 252 of the latch 248 in thegroove 218 of the next successive tooth 210 of the ratchet 204 by theaction of spring 257 urges the plate 194 to rotate to the nextsuccessive position. As the plate 194 begins rotating as a result of theforce imparted thereto by the lever 206, the pin 260 is urged out ofengagement with the aperture 270 in the plate 194 and rides along thesurface of the plate 194. As the plate 194 approaches the nextsuccessive position, the pin 260 of the locating mechanism 258 is biasedinto the next successive aperture 270 on the plate 194 and locks theplate 194 in the next successive discrete position.

The operation of the stud-driving assembly 208 will now be described asshown in FIGS. 14 and 15. As the upper die 14 is moved toward the lowerdie 12, the depending flange 510 on the upper die contacts the roundedflange 488 located on the first end 484 of the lever 472. As thedepending flange 510 is urged further downwardly by the upper die 14,the lever 472 is pivoted about the pin 492 so that the rounded flange490 on the second end 486 of the lever 472 is urged upwardly. Becausethe hammer 474 receives the second end 486 of the lever 472 within therecess 498 thereof, the hammer 474 is urged upwardly within the lateralrecess 480 of the housing 470 against the bias of the spring 508.

As the hammer 474 is moved upwardly by the second end 486 of the lever472, the distal end 506 of the extension 504 of the hammer 474 contactsthe stud 38 located in the gripping member 196 which is located adjacentthe web 18. As the hammer 474 is urged further upwardly by the secondend 486 of the lever 472, the arms 280 and 282 of the gripping member196 are forced apart against the bias of spring 288 by the action of theradially extending body of the stud 38 against the cam surface 292 onthe arms 280 and 282. The distal end 506 of the extension 504 therebyurges the stud 38 upwardly and free from engagement with the arms 280and 282 of the gripping member 196 and into a pre-formed aperture in theweb 18 where the stud 38 is lodged therein.

As the upper die 14 is moved upwardly with respect to the lower die 12,the flange 510 is lifted away from the first end 484 of the lever 472.The bias of the spring 508 thereby urges the hammer 474 downwardlywithin the lateral recess 480 of the housing 470 which, in turn, urgesthe second end 486 of the lever 472 downwardly therefrom. This downwardpivoting of the second end 486 of the lever 472 repositions the firstend 484 into the raised position as shown by the phantom outline in FIG.14.

It will be understood that the length and configuration of the flanges184, 294, and 510 can be selected so as to provide the actuation of thecar 80, lever 206, and the lever 472 at the proper time to provideoptimal results from the progressive die machine 10 during the operationthereof.

The bending apparatus 44 is shown in a lowered position in FIG. 16 andin a raised position in FIG. 17. It will be understood that when thebending apparatus 44 is located in the lowered position, less bend tothe part 40 is formed to the part 40. In addition, when the bendingapparatus 44 is positioned in the raised position, a more acute bend isprovided to the part 40.

Referring to FIGS. 16-17, the bending apparatus 44 comprises a steppermotor 300, a motion converter 302, and an adjustable floor device 304.It will be understood that, although the bending apparatus 44 is shownin FIG. 1 at forming station 32, the bending apparatus 44 can beprovided at any position in the progressive die machine 10 withoutdeparting from the scope of this invention. It will be furtherunderstood that the bending apparatus 44 can be configured as a separatedevice and retrofitted to a progressive die machine 10 or theprogressive die device can be integrally manufactured with theprogressive die machine 10.

The bending apparatus 44 is adapted to be located within the progressivedie machine 10 between the lower and upper dies 12 and 14, respectively.It will be understood that the stepper motor 300 and the adjustablefloor device are mounted to the lower die 12 by any conventional mannerwhich is well known in the art. It will be further understood that themotion converter 302 is mounted between the motor 300 and the adjustablefloor device 304.

The motor 300 can be any suitable device such as a housing 306 whichcontains a rotatable assembly which imparts rotary motion to an outputshaft 308 extending axially therefrom. Preferably, the motor 300 is adirect current (DC) stepper motor which can accurately provide preciseamounts of rotation to the output shaft 308 in discrete and/orcontinuous intervals.

The motion converter 302 comprises any suitable device for conversion ofrotary motion to rectilinear motion. For example, as shown in FIG. 16,the motion converter 302 comprises a housing 310 adapted to receive theoutput shaft 308 at a first end 312 and having a second end 314 fromwhich an output shaft 316 extends. The housing 310 preferably containscomponents which are commercially available and well known to convertrotary motion imparted to the output shaft 308 to linear motion whichextend and retract the output shaft 316 axially with respect to thehousing 310.

The adjustable floor device 304 comprises a lower portion 318 and anupper portion 320 mounted between a pair of stationary walls 322. Thewalls 322 are fixedly mounted to the lower die 12. The lower portion 318includes a ramped surface 324 which abuts the upper portion 320. Thelower portion 318 further has an end 326 mounted to a bracket 328 which,in turn, has a proximal end 330 adjacent the output shaft 316 of themotion converter 310. It will be understood that any axial movementimparted to the output shaft 316 of the motion converter 310 is impartedto the lower portion 318 of the adjustable floor device 304.

The upper portion 320 is slidably mounted within a recess 332 in thewalls 322 so that the upper portion is movable with respect to the walls322 but limited to a vertical direction. The upper portion 320 furtherhas a lower surface 334 thereon which abuts the ramped surface 324 onthe lower portion 318. A spring 336 is mounted axially on a shoulderfastener 338 which, in turn, is mounted to the upper portion 320 so thatthe shoulder fastener 338 downwardly biases the upper portion 320. Theshoulder fastener 338 extends between the lower die 12 and the upperportion 320 through a longitudinal slot (not shown) in the lower portion318 to allow for movement of the lower portion 318 with respect to theupper portion 320. The PLC 50 provides motion control to the motor 300.

It will be understood that the forming station 32 shown in FIG. 16includes a tool 344 thereon which generally comprises a downwardlydepending flange mounted to the upper die 14 and having a lower surface346 thereon which is adapted to form an upper limit to the contouringoperation performed by the bending apparatus 44. Further, the upperportion 320 of the adjustable floor device 304 includes an upper surface348 thereon which is adapted to provide a lower limit to the contouringoperation performed by the bending apparatus 44.

It will be understood that a part 40 formed by the web 18 is locatedbetween the lower and upper dies 12 and 14, respectively, as shown inFIG. 16. As is described elsewhere in this specification, the PLC 50 cansend a signal to the motor 300 through connection 342 to impart apredetermined degree of rotation to the output shaft 308. The rotationof the shaft 308 is converted to axial movement of the output shaft 316which is thereby extended or retracted depending upon the direction ofrotation of the output shaft 308. A spring return (not shown) can beprovided to urge the lower portion 318 toward the motor 300.

If the output shaft 316 is retracted toward the housing 310, the lowerportion 318 is also slid toward the motion converter 302. Theinteraction between the ramped surface 324 of the lower portion 318 andthe lower surface 334 of the upper portion 320 causes the upper portion320 to be lowered with respect to the walls 322. The upper surface 348of the upper portion 320 is thereby lowered a predetermined distance.

If the output shaft 316 is extended away from the housing 310, as shownalong arrow A of FIG. 17, the lower portion 318 is also slid away fromthe motion converter 302. The interaction between the ramped surface 324of the lower portion 318 and the lower surface 334 of the upper portion320 causes the upper portion 320 to be raised with respect to the walls322 as shown along arrow B of FIG. 17. The upper surface 348 of theupper portion 320 is thereby raised a predetermined distance.

It will be understood that the position of the upper surface 348 of theupper portion 320 of the adjustable floor device 304 determines theamount of bending introduced to the part 40 located at forming station32 as the tool 344 is lowered with the upper die 14 during the stroke ofthe progressive die machine 10. The lower surface 346 of the tool 344 isbrought into contact with the part 40 located there beneath and performsthe bending of the part 40 by forcing the part 40 between the lowersurface 346 of the tool 344 and the upper surface 348 of the upperportion 320 of the adjustable floor device 304.

Thus, upon an appropriate signal delivered to the motor 300, the uppersurface 348 of the upper portion 320 can be adjusted to provide a lesseror greater degree of bending depending upon the direction of rotation ofthe output shaft 308 of the motor 300. This degree of bending isdetermined by a quality control signal generated from the measuringapparatus 46.

The measuring apparatus 46 is shown in FIG. 18 comprising an upperportion 350 and a lower portion 352. It will be understood that themeasuring apparatus 46 can be manufactured as a separate assembly andretrofitted to an existing progressive die machine. Alternatively, themeasuring apparatus 46 can be manufactured as an integral portion of aprogressive die machine 10.

The upper portion 350 comprises a body 354 having an upper surface 356and a lower surface 358. The body 354 is provided with severalcylindrical bores 360 which extend through the body 354 between theupper and lower surfaces 356 and 358, respectively. The upper surface356 of the body 354 can be provided with a mounting assembly, such asshaft 362 shown in FIG. 18, for mounting the upper portion 350 to theupper die 14 of the progressive die machine. Alternatively, the upperportion 350 can be mounted to a separate lifting assembly (not shown)for raising and lowering the upper portion 350 with respect to the lowerportion 352. The lower surface 358 of the body 354 is provided with acentral flange 364 extending outwardly therefrom. The central flange 364is preferably provided with a downwardly-extending extension 366.

Each bore 360 in the upper portion 350 is adapted to receive atransducer 368 therein. Each of the transducers 368 in the upper portion350 comprise a transformer 370 having a core mounted therein for axialmovement with respect thereto. The transducers 368 are preferablymounted within the bores 360 of the upper portion 350 so that each ofthe cores 372 in the transducers 368 extends beyond the lower surface358 of the upper portion 350.

The lower portion 352 of the measuring apparatus 46 comprises a body 374having a table 376 mounted for vertical movement with respect to thebody 374. As with the upper portion 350 of the measuring apparatus 46,the lower portion 352 can either be mounted as a unit to a lower die 12of a progressive die machine 10 or mounted adjacent the die machine 10downstream from the forming stations 20-36.

The body 374 of the lower portion 352 includes an upper surface 378 anda lower surface 380 having several cylindrical bores 382 extendingtherebetween. In addition, the body 374 of the lower portion 352 isprovided with a pair of bearings 384 located adjacent each vertical sideof the body 374. Preferably, the bores 382 are located intermediate thebearings 384.

The table 376 comprises a plate 386 having an upper surface 388 and alower surface 390. Several apertures 392 extend through the plate 386between the upper and lower surfaces 388 and 390, respectively. Theapertures 392 are preferably located in a spaced lateral relationshipwith respect to one another. In addition, the apertures 392 and theplate 386 preferably correspond in vertical concentric alignment withthe bores 382 in the body 374 of the lower portion 352. The lowersurface 390 of the plate 386 is provided with at least two dependinglegs 394 located on adjacent opposite edges of the plate 386 whichpreferably correspond in vertical concentric alignment with the bearings384 on the body 374.

The table 376 is mounted to the body 374 by journaling the legs 394within the bearings 384 on the body 374. Springs 396 are preferablydisposed around the legs 394 between the lower surface 390 of the plate386 and the upper surface 378 of the body 374 so that the table 376 isbiased upwardly from the body 374. Further, transducers 398 having atransformer 400 and a core 402 mounted therein for axial movement withrespect to the transformer 400 are provided in the bores 382 of the body374. When the transducers 398 are mounted to the body 374, the cores 402of each of the transducers 398 preferably extend through the apertures392 in the plate 386 and beyond the upper surface 388 thereof.

It will be understood that the transducers 368 and 398 of the upper andlower portions 350 and 352, respectively, are properly interconnected tothe A/D converter 408 through the signal conditioning device 410.

It will be further understood that one of the transducers 398 on thelower portion 352 is also designed as a trigger device shown in FIG. 18by an additional reference numeral 406. The core 402 of the transducer406 is preferably in vertical alignment with the extension 366 on theupper portion 350. The extension 366 and transducer 406 are preferablylocated either forwardly or rearwardly of a plane containing theremaining transducers 368 and 398 for reasons which will be obvious asexplained below.

The trigger function of transducer 406 is to signal the initiation ofthe measurement process as well as provide a “zero” reference plane forcomparison with the remaining transducer 398. As the web 18 having aformed part 40 thereon is fed between the upper portion 350 and thelower portion 352 of the measuring apparatus 46, the extension 366 onthe upper portion 350 contacts the core 402 of the trigger transducer406 which causes the core 402 to be retracted within the transformer 400thereof. As the upper portion 350 continues to be lowered toward thelower portion 352, the cores 372 and 402 of the remaining transducers368 and 398 are urged against upper and lower surfaces of the part 40located therebetween. The lowering of the upper portion 350 toward thelower portion 352 causes the part 40 to be urged between the table 376and the upper portion 350 so that the table 376 is urged downwardlyagainst the bias of the springs 396 located between the body 374 andtable 376. This ensures that all of the transducers 368 and 398 obtaincontact with the part 40.

Once the transducers 368 on the upper portion 350 and the transducers398 on the lower portion 352 have sufficiently contacted the part 40,data is sent to a conventional analog-to-digital converter (not shown)which provides data information from the transducers 368 and 398 to thePLC 50 through the connections 440.

FIG. 19 shows a diagram of the process whereby a part 40 is measured bythe measuring apparatus 46. As shown in FIG. 19, the transducers 368 and398 send a signal through connections 404 to an analog-to-digitalconverter 408 (A/D converter). It will be understood that a signalconditioning device 410 can be mounted intermediate the transducers 368and 398 and the A/D converter 408 and is interconnected therebetween bysuitable connections 412.

The A/D converter 408 converts analog signals from the transducers 368and 398 into a digital format in a conventional manner which is wellknown in the art. The A/D converter 408 has an input port 414 and firstand second output ports 416 and 418. The input port 414 and first outputport 416 are interconnected by suitable connections 420 and 422,respectively, to a direct memory access (DMA) controller 426 of acomputer 424 DMA which, in turn, is interconnected by suitableconnections 428 to a random access memory (RAM) buffer 430. The RAM 430is interconnected by a suitable connection 432 to a central processingunit (CPU) 434 of any suitable type. An additional memory portion of thecomputer 424 contains a main program 436 which has access to the CPU 434through a suitable connection 438.

As data is read by the transducers 368 and 398 regarding the part 40located between the upper and lower portions 350 and 352, the data aresent through connection 404 through the signal conditioning device 410and into the A/D converter 408. The data is thereby converted to adigital signal and sent through the first output port 416 and throughconnection 422 into the DMA controller 426 in the computer 424. Thedigital signals are thereafter sent through connection 428 and stored inthe RAM 430.

The RAM 430, CPU 434 and main program 436 cooperate to determine whetherthe part 40 conforms with specifications for the part 40 which arepreferably suitably stored within the computer 424. The RAM 430, CPU 434and main program 436 cooperate to perform quality control analyses onthe digital data stored in the RAM 430.

First, the specific measurements of the part 40 located between theupper portion 350 and lower portion 352 of the measuring apparatus 46are compared with the part specifications stored in the computer 424 todetermine whether the part 40 located within the measuring apparatus 46falls within acceptable tolerance limits specified by the partspecifications. If the part 40 located within the measuring apparatus 46does not fall within acceptable tolerance limits as noted by the partspecifications, an error signal, which is generally referred to as “flag1,” is generated and is sent out of the computer 424 to the input port414 of the A/D converter 408.

The RAM 430, CPU 434 and main program 436 also track the number ofconsecutive “flag 1” error messages which were generated. If “flag 1”error messages were generated by the computer 424 for three consecutiveparts 40 located in the measuring apparatus 46, a second error message,identified as “flag 2,” is sent out of the computer 424 to the inputport 414 of the A/D converter 408.

Third, the RAM 430, CPU 434 and main program 436 cooperate to compute arolling average and variance of a previous predetermined number of parts40 which have passed through the measuring apparatus 46. It has beenfound that computing a rolling average and variance for the previous tenparts 40 which have passed through the measuring apparatus 46 providesan acceptable measure of the current performance of the progressive diemachine 10. However, a larger or smaller sample of the number of parts40 passing through the measuring apparatus 46 can be computed withoutdeparting from the scope of this invention. If the most recentlycomputed average and variance computations are determined to be too highor too low compared to the preferable values denoted by the partspecifications, a third error message, noted here as “flag 3,” is sentto the input port 414 of the A/D converter 408.

A value for the mean displacement of the transducers 368, 398 iscalculated. The mean is calculated using the well known equation:$\mu = \frac{\underset{l}{\sum\limits^{n}}X_{i}}{n}$

where:

X_(i)=the individual reading from each transducer 368, 398 on themeasuring apparatus 46;

n=the number of readings from the transducers 368, 398 which correspondsto the previous n parts passing through the measuring apparatus 46; and

μ=the calculated mean from the readings from transducers 368, 398.

A difference δ between the calculated mean μ and a target value τ of theparts formed is computed as follows:

δ=μ−τ

where:

δ=a calculated difference;

τ=a predefined desired target value.

A control signal σ is computed per the following formula:

σ=|δ|−λ

where:

δ=the difference as calculated above;

λ=a predefined tolerance limit for a formed part.

If necessary, the control signal is generated by the computer 424 andsent to the PLC 50 through the A/D converter 408 to adjust the bendingapparatus 44.

The PLC 50 preferably has first, second and third output ports 442, 444and 446, respectively. The first output port 442 is preferablyinterconnected to a sorting device 448 by a suitable connection 450. Thesorting device 448 preferably comprises a discharge chute provided witha diverter mechanism (not shown) whereby acceptable parts are depositedinto a first bin for accumulation and rejected parts are deposited intoa second bin for later disposal or recycling. The sorting device 448 canaccomplish this function using any suitable mechanism known in the artas the particular mechanism or device used to accomplish this functionshould not be interpreted as limiting the scope of this invention.

The second output port 444 is interconnected to a press control device452 by a suitable connection 454. The press control device 452 canpreferably, upon receipt of an appropriate signal, halt operation of theprogressive die machine 10. As with the sorting device 448, theparticular device used to accomplish the function of the press controldevice 452 should not be interpreted as limiting the scope of thisinvention.

The third output port 446 is interconnected to the bending apparatus 44by a suitable connection 456. It will be understood that the bendingapparatus 44 includes a controller (not shown) which is adapted toreceive signals from the PLC through the connection 456.

Upon receipt of a particular message from the computer 424 through theA/D converter 408, the PLC 50 can, in turn, send an appropriate signalto the sorting device 448, the press control device 452 and/or thebending apparatus 44. For example, if “flag 1” is received by the PLCfrom the A/D converter 408, the PLC 50 sends a signal through the firstoutput port 442 and connection 450 to the sorting device 448 to discardthe particular part 40 which is located in the measuring apparatus 46.If “flag 1” is not received by the PLC 50, the part 40 is determined tobe acceptable and will be deposited in a bin for accumulation.

If “flag 2” is received by the PLC 50 from the computer 424 through theA/D converter 408, the PLC 50 sends a suitable signal through the secondoutput port 444 and connection 454 to the press control device 452 tohalt operation of the progressive die machine 10. If “flag 2” is notreceived by the PLC 50, the operation of the progressive die machine 10will be continued.

If “flag 3” is received by the PLC 50 from the computer 424 through theA/D converter 408, a suitable signal is sent through the third outputport 446 and connection 456 to the bending apparatus 44 that the mean ofa recent number of parts 40 passing through the measuring apparatus 46are unacceptable with respect to the target part specification stored inthe computer 424. A signal is sent to the stepper motor 300 to raise orlower the adjustable floor device 304 with respect to the upper die 14so that subsequent parts 40 formed in the progressive die machine 10 atforming stations 20-36 correspond more closely to the specifications forthe parts 40.

FIG. 20 shows a diagram which outlines the events which occur during thestroke of the progressive die machine 10. The events and the particularangle notation at which the identified events occur should not beinterpreted as limiting the scope of this invention. It will beunderstood that the events shown can occur at other stroke angleswithout departing from the scope of this invention.

While particular embodiments of the invention have been shown, it willbe understood, of course, that the invention is not limited theretosince modifications may be made by those skilled in the art,particularly in light of the foregoing teachings. Reasonable variationand modification are possible within the scope of the foregoingdisclosure of the invention without departing from the spirit of theinvention.

What is claimed is:
 1. An apparatus for serially making formed partsfrom a web of deformable material and with a stud mounted thereincomprising: a plurality of progressive die forming stations for formingmultiple parts from the web by advancing the web through each formingstation; a feeding mechanism for feeding studs seriatim to apredetermined dispensing position adjacent to the web; a drivingmechanism adjacent to the web for inserting studs in spaced locationsinto the web; a transfer mechanism operably connected to the feedingmechanism for receiving studs from the feeding mechanism and fortransferring studs to the driving mechanism; and a cutting station forsevering the web after the web has passed through the die formingstations and after the insertion of a stud into the formed parts toseparate the formed parts from the web.
 2. The apparatus of claim 1wherein the driving mechanism is located adjacent to one of the dieforming stations whereby the studs are inserted into the web as theparts are formed in the progressive die forming stations.
 3. Theapparatus of claim 2 wherein the die forming stations further comprise:a moyable die having a driving ram associated therewith to reciprocatethe movable die between a retracted and a deforming position to deformthe web as the web is advanced through the forming stations; the drivingram is operably connected to the driving mechanism to actuate thedriving mechanism for inserting a stud into the web when the movable dieis moved between the retracted and deforming positions.
 4. The apparatusof claim 3 wherein the operable connection between the driving ram andthe driving mechanism comprises: one of a flange and a socket disposedon the movable die; and the other of the flange and the socket locatedon the driving mechanism; whereby when the movable die is moved betweenthe retracted and the deforming positions the flange is received in thesocket.
 5. The apparatus of claim 3 wherein the feeding mechanism ispositioned adjacent one of the forming stations and is operablyinterconnected with the driving ram to index the seriatim feeding of thestuds when the movable die is moved between the retracted and deformingpositions.
 6. The apparatus of claim 5 wherein the feeding mechanismcomprises: a shuttle car movable between a receiving position and adispensing position and having an opening for receiving one of the studstherein when in the receiving position, the opening in the shuttle caris aligned with a conduit in the feeding mechanism, one end of theconduit is aligned with the opening in the shuttle car when in thedispensing position, the other end of the conduit is aligned with thetransfer mechanism, the shuttle car having a cam follower; and a camoperably connected to the driving ram in register with the cam followerfor moving the shuttle car from the receiving position to the dispensingposition as the movable die moves between the retracted and deformingpositions.
 7. The apparatus of claim 6 wherein the feeding mechanismfurther comprises an actuator mounted adjacent to the shuttle car andadapted to move the stud out of the opening in the shuttle car into theconduit when the shuttle car is moved to the dispensing position.
 8. Theapparatus of claim 7 wherein the actuator comprises a pressurized airnozzle in register with the opening of the shuttle car in the dispensingposition whereby air exiting the nozzle moves the stud into the conduit.9. The apparatus of claim 8 wherein the feeding mechanism furthercomprises: a lever mounted adjacent to an end of the conduit having astop thereon movable between an obstructing position and a releaseposition; a cylinder having an axially-movable piston having an actuatorportion thereon in register with the lever, the piston being movablebetween a first position wherein the actuator portion positions thelever in the obstructing position and a second position wherein theactuator portion positions the lever in the release position and forcesthe stud out of an exit of the conduit and into the transfer mechanism.10. The apparatus of claim 9 wherein the piston further comprises astud-receiving indentation which receives the stud as the piston movesfrom the first position to the second position for restricting themovement of the stud in a single linear direction.
 11. The apparatus ofclaim 1 wherein the transfer mechanism positioned adjacent one of theforming stations and is operably interconnected with the driving ram toindex the seriatim feeding of the studs between the feeding mechanismand the driving mechanism when the movable die is moved between theretracted and deforming positions.
 12. The apparatus of claim 11 whereinthe transfer mechanism comprises: a support plate; at least one set ofgripping members mounted to the support plate and adapted to selectivelygrip a stud; the support plate is mounted for movement of the at leastone set of gripping members between the feeding mechanism and thedriving mechanism; whereby the at least one set of gripping membersreceive and grip a stud from the feeding mechanism, travel with thesupport plate to the driving mechanism, and release the stud at thedriving mechanism.
 13. The apparatus of claim 12 wherein the transfermechanism further comprises an arm mounted to the support plate througha ratchet mechanism to selectively position the support plate at anumber of discrete positions between the feeding mechanism and thedriving mechanism.
 14. The apparatus of claim 13 wherein the arm has aflange operably coupled to the driving ram so that the arm positions thesupport plate at a next discrete position as the movable die movesbetween the retracted and deforming positions.
 15. The apparatus ofclaim 14 wherein the at least one set of gripping members comprisesmultiple sets of gripping members mounted to the support plate whereinone of the sets of gripping members is positioned at the feedingmechanism and another of the sets of gripping members is positioned atthe driving mechanism at each discrete position of the support plate.16. The apparatus of claim 15 wherein the driving mechanism ispositioned adjacent one of the forming stations and is operablyinterconnected with the driving ram to index the seriatim insertion ofthe studs into the web when the movable die is moved between theretracted and deforming positions.
 17. The apparatus of claim 16 whereinthe driving mechanism comprises: a driving mechanism housing; a hammerslidably mounted within the housing and adjacent to the transfermechanism for forcing each of the studs into the web; and a levermounted to the housing for movement between a rest position and aninsertion position and having a first end and a second end, the firstend operably connected to the driving ram and the second end in registerwith the hammer, wherein hammer receives one of the studs when the leveris in the rest position and the hammer is moved by the lever to insertthe stud into the web when the lever moves between the rest andinsertion positions; whereby the lever is moved between the restposition and the insertion position when the movable die is movedbetween the retracted position and the deforming position.
 18. Theapparatus of claim 1 wherein the die forming stations further comprise:a movable die having a driving ram associated therewith to reciprocatethe movable die between a retracted and a deforming position to deformthe web as the web is advanced through the forming stations; the drivingram is operably connected to the driving mechanism to actuate thedriving mechanism for inserting a stud into the web when the movable dieis moved between the retracted and deforming positions.
 19. Theapparatus of claim 18 wherein the operable connection between thedriving ram and the driving mechanism comprises: one of a flange and asocket disposed on the movable die; and the other of the flange and thesocket located on the driving mechanism; whereby when the movable die ismoved between the retracted and the deforming positions the flange isreceived in the socket.
 20. The apparatus of claim 1 wherein the feedingmechanism is positioned adjacent one of the forming stations and isoperably interconnected with a driving ram to index the seriatim feedingof the studs when a movable die is moved between retracted and deformingpositions.
 21. The apparatus of claim 20 wherein the feeding mechanismcomprises: a shuttle car movable between a receiving position and adispensing position and having an opening for receiving one of the studstherein when in the receiving position, the opening in the shuttle caris aligned with a conduit in the feeding mechanism, one end of theconduit is aligned with the opening in the shuttle car when in thedispensing position, the other end of the conduit is aligned with thetransfer mechanism, the shuttle car having a cam follower; and a camoperably connected to the driving ram in register with the cam followerfor moving the shuttle car from the receiving position to the dispensingposition as the movable die moves between the retracted and deformingpositions.
 22. The apparatus of claim 1 wherein the feeding mechanismfurther comprises an actuator mounted adjacent to a shuttle car havingan opening and adapted to move the stud out of the opening in theshuttle car into a conduit when the shuttle car is moved to a dispensingposition.
 23. The apparatus of claim 22 wherein the actuator comprises apressurized air nozzle in register with the opening of the shuttle carin the dispensing position whereby air exiting the nozzle moves the studinto the conduit.
 24. The apparatus of claim 1 wherein the feedingmechanism further comprises: a conduit extending between the feedingmechanism and the transfer mechanism; a lever mounted adjacent to an endof the conduit having a stop thereon movable between an obstructingposition and a release position; a cylinder having an axially-movablepiston having an actuator portion thereon in register with the lever,the piston being movable between a first position wherein the actuatorportion positions the lever in the obstructing position and a secondposition wherein the actuator portion positions the lever in the releaseposition and forces the stud out of an exit of the conduit and into thetransfer mechanism.
 25. The apparatus of claim 24 wherein the pistonfurther comprises a stud-receiving indentation which receives the studas the piston moves from the first position to the second position forrestricting the movement of the stud in a single linear direction. 26.The apparatus of claim 1 wherein the transfer mechanism is positionedadjacent one of the forming stations and is operably interconnected witha driving ram to index the seriatim feeding of the studs between thefeeding mechanism and the driving mechanism when a movable die is movedbetween retracted and deforming positions.
 27. The apparatus of claim 26wherein the transfer mechanism comprises: a support plate; at least oneset of gripping members mounted to the support plate and adapted toselectively grip a stud; the support plate is mounted for movement ofthe at least one set of gripping members between the feeding mechanismand the driving mechanism; whereby the at least one set of grippingmembers receive and grip a stud from the feeding mechanism, travel withthe support plate to the driving mechanism, and release the stud at thedriving mechanism.
 28. The apparatus of claim 1 wherein the transfermechanism further comprises an arm mounted to a support plate through aratchet mechanism to selectively position the support plate at a numberof discrete positions between the feeding mechanism and the drivingmechanism.
 29. The apparatus of claim 28 wherein the arm has a flangeoperably coupled to a driving ram so that the arm positions the supportplate at a next discrete position as a movable die moves betweenretracted and deforming positions.
 30. The apparatus of claim 29 whereinthe at least one set of gripping members comprises multiple sets ofgripping members mounted to the support plate wherein one of the sets ofgripping members is positioned at the feeding mechanism and another ofthe sets of gripping members is positioned at the driving mechanism ateach discrete position of the support plate.
 31. The apparatus of claim1 wherein the driving mechanism is positioned adjacent one of theforming stations and is operably interconnected with a driving ram toindex the seriatim insertion of the studs into the web when a movabledie is moved between retracted and deforming positions.
 32. Theapparatus of claim 31 wherein the driving mechanism comprises: a drivingmechanism housing; a hammer slidably mounted within the housing andadjacent to the transfer mechanism for forcing each of the studs intothe web; and a lever mounted to the housing for movement between a restposition and an insertion position and having a first end and a secondend, the first end operably connected to the driving ram and the secondend in register with the hammer, wherein hammer receives one of thestuds when the lever is in the rest position and the hammer is moved bythe lever to insert the stud into the web when the lever moves betweenthe rest and insertion positions; whereby the lever is moved between therest position and the insertion position when the movable die is movedbetween retracted and deforming positions.
 33. An apparatus for seriallymaking formed parts from a web of deformable material and with a studmounted therein comprising: a plurality of progressive die formingstations for forming multiple parts from the web by advancing the webthrough each forming station, wherein the plurality of die formingstations further comprises a movable die having a driving ram associatedtherewith to reciprocate the movable die between a retracted and adeforming position to deform the web as the web is advanced through theforming stations, and the driving ram is operably connected to a drivingmechanism to actuate the driving mechanism for inserting a stud into theweb when the movable die is moved between the retracted and deformingpositions; a feeding mechanism for feeding studs seriatim to apredetermined dispensing position adjacent to the web; the drivingmechanism is positioned adjacent to the web for inserting studs inspaced locations into the web, wherein the driving mechanism is locatedadjacent to one of the die forming stations whereby the studs areinserted into the web as the parts are formed in the progressive dieforming stations, wherein the operable connection between the drivingram and the driving mechanism comprises one of a flange and a socketdisposed on the movable die, and the other of the flange and the socketlocated on the driving mechanism whereby when the movable die is movedbetween the retracted and the deforming positions the flange is receivedin the socket; a transfer mechanism operably connected to the feedingmechanism for receiving studs from the feeding mechanism and fortransferring studs to the driving mechanism; and a cutting station forsevering the web after the web has passed through the die formingstations to separate the formed individual stud-bearing parts from theweb.
 34. The apparatus of claim 33 wherein the feeding mechanism ispositioned adjacent one of the forming stations and is operablyinterconnected with the driving ram to index the seriatim feeding of thestuds when the movable die is moved between the retracted and deformingpositions.
 35. The apparatus of claim 34 wherein the feeding mechanismcomprises: a shuttle car movable between a receiving position and adispensing position and having an opening for receiving one of the studstherein when in the receiving position, the opening in the shuttle caris aligned with a conduit in the feeding mechanism, one end of theconduit is aligned with the opening in the shuttle car when in thedispensing position, the other end of the conduit is aligned with thetransfer mechanism, the shuttle car having a cam follower; and a camoperably connected to the driving ran in register with the cam followerfor moving the shuttle car from the receiving position to the dispensingposition as the movable die moves between the retracted and deformingpositions.
 36. The apparatus of claim 35 wherein the feeding mechanismfurther comprises an actuator mounted adjacent to the shuttle car andadapted to move the stud out of the opening in the shuttle car into theconduit when the shuttle car is moved to the dispensing position. 37.The apparatus of claim 36 wherein the actuator comprises a pressurizedair nozzle in register with the opening of the shuttle car in thedispensing position whereby air exiting the nozzle moves the stud intothe conduit.
 38. The apparatus of claim 37 wherein the feeding mechanismfurther comprises: a lever mounted adjacent to an end of the conduithaving a stop thereon movable between an obstructing position and arelease position; a cylinder having an axially-movable piston having anactuator portion thereon in register with the lever, the piston beingmovable between a first position wherein the actuator portion positionsthe lever in the obstructing position and a second position wherein theactuator portion positions the lever in the release position and forcesthe stud out of an exit of the conduit and into the transfer mechanism.39. The apparatus of claim 38 wherein the piston further comprises astud-receiving indentation which receives the stud as the piston movesfrom the first position to the second position for restricting themovement of the stud in a single linear direction.
 40. An apparatus forserially making formed parts from a web of deformable material and witha stud mounted therein comprising: a plurality of progressive dieforming stations for forming multiple parts from the web by advancingthe web through each forming station; a feeding mechanism for feedingstuds seriatim to a predetermined dispensing position adjacent to theweb; a driving mechanism adjacent to the web for inserting studs inspaced locations into the web; a transfer mechanism operably connectedto the feeding mechanism for receiving studs from the feeding mechanismand for transferring studs to the driving mechanism, wherein thetransfer mechanism positioned adjacent one of the forming stations andis operably interconnected with a driving ram having a movable die toindex the seriatim feeding of the studs between the feeding mechanismand the driving mechanism when the movable die is moved betweenretracted and deforming positions, wherein the transfer mechanismfurther comprises: a support plate; at least one set of gripping membersmounted to the support plate and adapted to selectively grip a stud; thesupport plate is mounted for movement of the at least one set ofgripping members between the feeding mechanism and the drivingmechanism; whereby the at least one set of gripping members receive andgrip a stud from the feeding mechanism, travel with the support plate tothe driving mechanism, and release the stud at the driving mechanism;and a cutting station for severing the web after the web has passedthrough the die forming stations to separate individual stud-bearingformed parts from the web.
 41. The apparatus of claim 40 wherein thetransfer mechanism further comprises an arm mounted to the support platethrough a ratchet mechanism to selectively position the support plate ata number of discrete positions between the feeding mechanism and thedriving mechanism.
 42. The apparatus of claim 41 wherein the arm has aflange operably coupled to the driving ram so that the arm positions thesupport plate at a next discrete position as the movable die movesbetween retracted and deforming positions.
 43. The apparatus of claim 41wherein the at least one set of gripping members comprises multiple setsof gripping members mounted to the support plate wherein one of the setsof gripping members is positioned at the feeding mechanism and anotherof the sets of gripping members is positioned at the driving mechanismat each discrete position of the support plate.
 44. The apparatus ofclaim 43 wherein the driving mechanism is positioned adjacent one of theforming stations and is operably interconnected with the driving ram toindex the seriatim insertion of the studs into the web when the movabledie is moved between the retracted and deforming positions.
 45. Theapparatus of claim 44 wherein the driving mechanism comprises: a drivingmechanism housing; a hammer slidably mounted within the housing andadjacent to the transfer mechanism for forcing each of the studs intothe web; and a lever mounted to the housing for movement between a restposition and an insertion position and having a first end and a secondend, the first end operably connected to the driving ram and the secondend in register with the hammer, wherein hammer receives one of thestuds when the lever is in the rest position and the hammer is moved bythe lever to insert the stud into the web when the lever moves betweenthe rest and insertion positions; whereby the lever is moved between therest position and the insertion position when the movable die is movedbetween the retracted position and the deforming position.
 46. Anapparatus for serially making formed parts from a web of deformablematerial and with a stud mounted therein comprising: a plurality ofprogressive die forming stations for forming multiple parts from the webby advancing the web through each forming station, wherein the dieforming stations further comprise a movable die having a driving ramassociated therewith to reciprocate the movable die between a retractedand a deforming position to deform the web as the web is advancedthrough the forming stations; a feeding mechanism for feeding studsseriatim to a predetermined dispensing position adjacent to the web; adriving mechanism adjacent to the web for inserting studs in spacedlocations into the web, wherein the driving ram is operably connected tothe driving mechanism to actuate the driving mechanism for inserting astud into the web when the movable die is moved between the retractedand deforming positions; a transfer mechanism operably connected to thefeeding mechanism for receiving studs from the feeding mechanism and fortransferring studs to the driving mechanism; and a cutting station forsevering the web after the web has passed through the die formingstations to separate formed individual stud-bearing parts from the web.47. The apparatus of claim 46 wherein the operable connection betweenthe driving ram and the driving mechanism comprises: one of a flange anda socket disposed on the movable die; and the other of the flange andthe socket located on the driving mechanism; whereby when the movabledie is moved between the retracted and the deforming positions theflange is received in the socket.
 48. An apparatus for serially makingformed parts from a web of deformable material and with a stud mountedtherein comprising: a plurality of progressive die forming stations forforming multiple parts from the web by advancing the web through eachforming station; a feeding mechanism for feeding studs seriatim to apredetermined dispensing position adjacent to the web, wherein thefeeding mechanism is positioned adjacent one of the forming stations andis operably interconnected with a driving ram to index the seriatimfeeding of the studs when a movable die is moved between retracted anddeforming positions; a driving mechanism adjacent to the web forinserting studs in spaced locations into the web; a transfer mechanismoperably connected to the feeding mechanism for receiving studs from thefeeding mechanism and for transferring studs to the driving mechanism;and a cutting station for severing the web after the web has passedthrough the die forming stations to separate formed individualstud-bearing parts from the web.
 49. The apparatus of claim 48 whereinthe feeding mechanism comprises: a shuttle car movable between areceiving position and a dispensing position and having an opening forreceiving one of the studs therein when in the receiving position, theopening in the shuttle car is aligned with a conduit in the feedingmechanism, one end of the conduit is aligned with the opening in theshuttle car when in the dispensing position, the other end of theconduit is aligned with the transfer mechanism, the shuttle car having acam follower; and a cam operably connected to the driving ram inregister with the cam follower for moving the shuttle car from thereceiving position to the dispensing position as the movable die movesbetween the retracted and deforming positions.
 50. The apparatus ofclaim 49 wherein the feeding mechanism further comprises an actuatormounted adjacent to the shuttle car and adapted to move the stud out ofthe opening in the shuttle car into the conduit when the shuttle car ismoved to the dispensing position.
 51. The apparatus of claim 50 whereinthe actuator comprises a pressurized air nozzle in register with theopening of the shuttle car in the dispensing position whereby airexiting the nozzle moves the stud into the conduit.
 52. The apparatus ofclaim 51 wherein the feeding mechanism further comprises: a levermounted adjacent to an end of the conduit having a stop thereon movablebetween an obstructing position and a release position; a cylinderhaving an axially-movable piston having an actuator portion thereon inregister with the lever, the piston being movable between a firstposition wherein the actuator portion positions the lever in theobstructing position and a second position wherein the actuator portionpositions the lever in the release position and forces the stud out ofan exit of the conduit and into the transfer mechanism.
 53. Theapparatus of claim 52 wherein the piston further comprises astud-receiving indentation which receives the stud as the piston movesfrom the first position to the second position for restricting themovement of the stud in a single linear direction.
 54. An apparatus forserially making formed parts from a web of deformable material and witha stud mounted therein comprising: a plurality of progressive dieforming stations for forming multiple parts from the web by advancingthe web through each forming station; a feeding mechanism for feedingstuds seriatim to a predetermined dispensing position adjacent to theweb; a driving mechanism adjacent to the web for inserting studs inspaced locations into the web; a transfer mechanism operably connectedto the feeding mechanism for receiving studs from the feeding mechanismand for transferring studs to the driving mechanism, wherein thetransfer mechanism positioned adjacent one of the forming stations andis operably interconnected with a driving ram having a movable die toindex the seriatim feeding of the studs between the feeding mechanismand the driving mechanism when the movable die is moved betweenretracted and deforming positions; and a cutting station for severingthe web after the web has passed through the die forming stations toseparate formed individual stud-bearing parts from the web.
 55. Theapparatus of claim 54 wherein the transfer mechanism comprises: asupport plate; at least one set of gripping members mounted to thesupport plate and adapted to selectively grip a stud; the support plateis mounted for movement of the at least one set of gripping membersbetween the feeding mechanism and the driving mechanism; whereby the atleast one set of gripping members receive and grip a stud from thefeeding mechanism, travel with the support plate to the drivingmechanism, and release the stud at the driving mechanism.
 56. Theapparatus of claim 55 wherein the transfer mechanism further comprisesan arm mounted to the support plate through a ratchet mechanism toselectively position the support plate at a number of discrete positionsbetween the feeding mechanism and the driving mechanism.
 57. Theapparatus of claim 56 wherein the arm has a flange operably coupled tothe driving ram so that the arm positions the support plate at a nextdiscrete position as the movable die moves between the retracted anddeforming positions.
 58. The apparatus of claim 57 wherein the at leastone set of gripping members comprises multiple sets of gripping membersmounted to the support plate wherein one of the sets of gripping membersis positioned at the feeding mechanism and another of the sets ofgripping members is positioned at the driving mechanism at each discreteposition of the support plate.
 59. An apparatus for serially makingformed parts from a web of deformable material and with a stud mountedtherein comprising: a plurality of progressive die forming stations forforming multiple parts from the web by advancing the web through eachforming station; a feeding mechanism for feeding studs seriatim to apredetermined dispensing position adjacent to the web; a drivingmechanism adjacent to the web for inserting studs in spaced locationsinto the web, wherein the driving mechanism is positioned adjacent oneof the forming stations and is operably interconnected with a drivingram having a movable die to index the seriatim insertion of the studsinto the web when the movable die is moved between retracted anddeforming positions, wherein the driving mechanism further comprises: adriving mechanism housing; a hammer slidably mounted within the housingand adjacent to the transfer mechanism for forcing each of the studsinto the web; and a lever mounted to the housing for movement between arest position and an insertion position and having a first end and asecond end, the first end operably connected to the driving ram and thesecond end in register with the hammer, wherein hammer receives one ofthe studs when the lever is in the rest position and the hammer is movedby the lever to insert the stud into the web when the lever movesbetween the rest and insertion positions; whereby the lever is movedbetween the rest position and the insertion position when the movabledie is moved between the retracted position and the deforming position;a transfer mechanism operably connected to the feeding mechanism forreceiving studs from the feeding mechanism and for transferring studs tothe driving mechanism; and a cutting station for severing the web afterthe web has passed through the die forming stations to separate formedindividual stud-bearing parts from the web.